Methods of forming desired geometry on superalloy part using powder mixture of low and high melt temperature superalloys

Abstract

Methods of forming a desired geometry at a location on a superalloy part are disclosed. The method may include directing particles of a powder mixture including a low melt temperature superalloy powder and a high melt temperature superalloy powder to the location on the superalloy part at a velocity sufficient to cause the superalloy powders to deform and to form a mechanical bond but not metallurgical bond to the superalloy part. The directing of particles continues until the desired geometry is formed. Heat is applied to the powder mixture on the repair location. The heat causes the low melt temperature superalloy powder to melt, creating the metallurgical bonding at the location. Another method uses the same directing to form a preform for repairing the location on the part. The low melt temperature superalloy powder melts at <1287° C., and the high melt temperature superalloy powder melts at >1287° C.

What is claimed is: 
     
       1. A method, comprising:
 creating a preform by directing particles of a powder mixture including a low melt temperature superalloy powder and a high melt temperature superalloy powder onto a build plate at a velocity sufficient to cause the superalloy powders to deform and to form a mechanical bond but not a metallurgical bond to the build plate; and 
 applying heat to the preform after having the preform: removed from the build plate, shaped into a desired geometry for a location of a superalloy part, and positioned in the location of the superalloy part, 
 wherein the heat applying causes the low melt temperature superalloy powder to melt and form a metallurgical bond with the superalloy part, 
 wherein the low melt temperature superalloy powder has a melt temperature less than 1287° Celsius (° C.), and the high melt temperature superalloy powder has a melt temperature greater than 1287° C. 
 
     
     
       2. The method of  claim 1 , further comprising positioning the preform in the location of the superalloy part. 
     
     
       3. The method of  claim 1 , wherein shaping the preform includes cutting unwanted material away from the preform. 
     
     
       4. The method of  claim 1 , wherein the superalloy part is additively manufactured. 
     
     
       5. The method of  claim 1 , wherein the superalloy part is cast. 
     
     
       6. The method of  claim 1 , further comprising machining the location of the superalloy part after the heat applying. 
     
     
       7. The method of  claim 1 , wherein the low melt temperature superalloy powder is a nickel-based superalloy. 
     
     
       8. The method of  claim 1 , wherein the high melt temperature superalloy powder is a nickel-based superalloy. 
     
     
       9. The method of  claim 1 , wherein, during the heat applying, the high melt temperature superalloy powder remains in solid form. 
     
     
       10. A method, comprising:
 creating a preform by directing particles of a powder mixture including a low melt temperature superalloy powder and a high melt temperature superalloy powder onto a build plate at a velocity sufficient to cause the superalloy powders to deform and to form a mechanical bond but not a metallurgical bond to the build plate; and 
 removing the preform from the build plate allowing subsequent shaping into a desired geometry for a location on a superalloy part, 
 wherein the low melt temperature superalloy powder has a melt temperature less than 1287° Celsius (° C.), and the high melt temperature superalloy powder has a melt temperature greater than 1287° C.